Tubular assembly for an aerosol generating article and method of manufacture

Abstract

A method of manufacturing a tubular assembly of an aerosol-generating article for use in a non-combustible aerosol delivery system is disclosed. The method comprises applying a body of flexible material to a layer of packaging material and subsequently forming the layer with the body of material applied thereto into a tubular assembly, wherein the body of material is surrounded by the layer of packaging material. A tubular assembly of an aerosol-generating article for use in a non-combustible aerosol provision system, an article for use in a non-combustible aerosol provision system comprising an aerosol-generating device, and a system comprising a non-combustible aerosol-generating device are also disclosed.

Description

[0001] This invention relates to a method for manufacturing a tubular assembly of an aerosol generating article for use in a non-flammable aerosol supply system. The invention also relates to a tubular assembly of an aerosol generating article for use in a non-flammable aerosol supply system, an aerosol generating article for use in a non-flammable aerosol supply system including an aerosol generating device, and a system including a non-flammable aerosol generating device and an aerosol generating article.

[0002] background Some tobacco industry products generate aerosols that are inhaled by the user during use. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, by heating (but not burning) the substrate to form an aerosol. Such tobacco industry products typically include a mouthpiece through which the aerosol is delivered to the user's mouth.

[0003] Overview According to some embodiments described herein, a method is provided for manufacturing a tubular assembly of an aerosol generating article for use in a non-flammable aerosol delivery system, comprising applying a flexible material body to a packaging material layer and subsequently shaping the layer together with the material body applied thereto into a tubular assembly, wherein the material body is encircled by the packaging material layer.

[0004] The material body can be applied to the layer while the layer is substantially planar.

[0005] The thickness to which the material body is applied on the layer can be greater than the thickness of the layer.

[0006] The method may include shaping the layer and the material body applied thereto together into a tubular assembly by wrapping the layer together with the material body applied thereto around a cylindrical mandrel.

[0007] A method of forming the layer together with a body of material applied thereto into a tubular assembly may include applying an adhesive to the layer such that the edges of the layers that come into contact with each other when the layers are wound around a cylindrical mandrel are bonded together.

[0008] The material body can be adhered to the layer using an adhesive.

[0009] In some embodiments, the material body may be nonwoven cellulose, such that the method includes applying nonwoven cellulose to the layer.

[0010] In other embodiments, the material body may be paper, such that the method includes applying the paper to the layer. Prior to application to the layer, the paper may be crimped or corrugated.

[0011] The material body can be applied to the packaging material layers in layers. The material body can be pre-formed into a laminated structure before being applied to the layers. Alternatively, these layers can be applied sequentially to the packaging material layers. These layers can be bonded together with adhesives.

[0012] In some embodiments, the method may include applying the material body in a liquid or other non-solid form to the packaging material layer, allowing it to cure first, and then shaping the layer and the material body applied thereto into a tubular assembly. Applying the material body in liquid form may include spraying, coating, or printing onto the layer.

[0013] In some embodiments, the method may include applying the material body to the layer in spaced elongated strips or lines such that, when the layer and the material body applied thereto are formed into a tubular assembly, the elongated strips or lines extend in a longitudinal direction parallel to the longitudinal axis of the tubular assembly.

[0014] Applying the material body in spaced, elongated strips or lines allows gaps to be maintained between each strip when the layer is formed together with the material body applied thereto into a tubular assembly.

[0015] In an alternative embodiment, the material body can be applied to the layer such that it extends continuously across the layer. The material can extend across the packaging material layer to a uniform thickness. Alternatively, the material body can be applied such that its thickness varies in the direction of extension across the layer. The thickness can vary according to a defined pattern, i.e., the material body can have a corrugated profile. Alternatively, the thickness of the material body can be irregular across the entire packaging material layer.

[0016] The method may include the following steps: forming an elongated rod by winding the layer together with a body of material applied thereto around a mandrel, and subsequently cutting the rod at spaced intervals to form a plurality of individual tubular assemblies.

[0017] According to another embodiment described herein, a tubular assembly of an aerosol generating article for use in a non-flammable aerosol supply system is provided, the tubular assembly having a longitudinal axis and comprising a material body surrounded by an outer packaging material layer, wherein the material body comprises a plurality of layers.

[0018] At least one layer of the material body may be formed of a nonwoven material such as cellulose.

[0019] At least one of the plurality of layers may be formed of paper. The paper may be wrinkled and formed of strips. Alternatively, the paper may have a corrugated profile.

[0020] These layers, or some of these layers, can be adhered to each other with adhesive.

[0021] Two or more of the multiple layers may be formed of the same or different materials.

[0022] The outer packaging material layer can be formed of paper.

[0023] The tubular assembly may further include an inner layer serving as a liner for the material body. The inner layer may be formed of the same material as the outer layer.

[0024] According to another embodiment described herein, a tubular assembly of an aerosol generating article for use in a non-flammable aerosol supply system is provided, the tubular assembly having a longitudinal axis and comprising a material body surrounded by an outer packaging material layer, wherein the material body comprises a plurality of longitudinally extending circumferentially spaced strips, each of which extends radially inward toward the longitudinal axis.

[0025] Each strip may extend parallel to the longitudinal axis.

[0026] Each strip can narrow in a radially inward direction toward the longitudinal axis and terminate at a tip.

[0027] Each strip can be shaped such that the strip edge extending between the outer packaging material layer and the tip is parallel to the facing edge of the adjacent strip.

[0028] The tip of each strip can be closer to the longitudinal axis in the radial direction than to the outer sheet.

[0029] The tip of each strip may include a surface that extends circumferentially around the longitudinal axis.

[0030] The surface forming the tip can be arc-shaped, and the curvature axis of each surface can be coaxial with the longitudinal axis of the tubular assembly.

[0031] According to another embodiment described herein, an article is provided for use in a non-flammable aerosol supply system including an aerosol generating device, the article comprising a hollow tubular component made according to the method of the invention.

[0032] According to another embodiment described herein, an article is provided for use in a non-flammable aerosol supply system including an aerosol generating device, the article comprising a tubular component according to the invention.

[0033] According to another embodiment described herein, a system is provided that includes a non-flammable aerosol generator, the non-flammable aerosol generator including a heating element and an aerosol generating article according to the invention. Brief description of the attached diagram Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 This is a side cross-sectional view of an aerosol generating article for a non-flammable aerosol supply device according to one embodiment of the present invention; Figure 2a shows the passage along line AA, according to a first embodiment of the present invention. Figure 1 The cross-section of a hollow tubular component of an aerosol generating product; Figure 2b shows the outer sheet of the hollow tubular assembly of Figure 2a, wherein the material body has been applied to the outer sheet and before the outer sheet and the material body are formed together into the tubular assembly; Figure 3a shows the passage along line AA, according to a second embodiment of the present invention. Figure 1 The cross-section of a hollow tubular component of an aerosol generating product; Figure 3b shows the outer sheet of the hollow tubular assembly of Figure 3a, wherein the material body has been applied to the outer sheet and before the outer sheet and the material body are formed together into the tubular assembly; Figure 4a shows the passage along line AA, according to a third embodiment of the present invention. Figure 1 The cross-section of a hollow tubular component of an aerosol generating product; Figure 4b shows the outer sheet of the hollow tubular assembly of Figure 4a, wherein the material body has been applied to the outer sheet and before the outer sheet and the material body are formed together into the tubular assembly; Figure 5 This is a simplified cross-sectional view of a non-flammable aerosol supply system including an aerosol supply device having inserts therein, such as... Figure 1 to any of the aerosol generating articles shown in Figure 4; and Figure 6 yes Figure 5 A simplified schematic diagram of the components of the aerosol supply device shown.

[0035] Detailed Explanation As used herein, the term "delivery system" is intended to cover systems that deliver at least one substance to a user, and includes: Combustible aerosol supply systems, such as cigarettes, cigarettes, cigars, and tobacco (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokeable materials) for pipes, roll-your-own cigarettes, or make-your-own cigarettes. Non-flammable aerosol supply systems, which generate aerosols by releasing compounds from aerosol generating materials without burning the materials themselves, such as electronic cigarettes, heated tobacco products, and hybrid systems that use a combination of aerosol generating materials to generate aerosols; and A non-aerosol delivery system that delivers at least one of the substances to a user orally, nasally, percutaneously, or otherwise without forming an aerosol, including but not limited to lozenges, chewing gum, patches, articles containing inhalable powder, and oral products such as oral tobacco including snuff or wet snuff, wherein the at least one substance may or may not contain nicotine.

[0036] According to this disclosure, a "non-flammable" aerosol supply system is an aerosol supply system in which the aerosol generating material of the aerosol supply system (or its components) does not burn or incinerate to facilitate the delivery of at least one substance to a user.

[0037] In some implementations, the delivery system is a non-flammable aerosol supply system, such as an electrically powered non-flammable aerosol supply system.

[0038] In some implementations, the non-flammable aerosol supply system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not required.

[0039] In some implementations, the non-combustible aerosol supply system is an aerosol generating material heating system, also known as a heated non-combustible system. An example of such a system is a tobacco heating system.

[0040] In some embodiments, the non-flammable aerosol supply system is a hybrid system that uses a combination of aerosol-generating materials to generate aerosols, wherein one or more aerosol-generating materials can be heated. Each of the aerosol-generating materials can be in, for example, solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the hybrid system comprises liquid or gel aerosol-generating materials and solid aerosol-generating materials. Solid aerosol-generating materials may comprise, for example, tobacco or non-tobacco products.

[0041] Typically, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables used with the non-flammable aerosol supply device.

[0042] One embodiment of this disclosure relates to a component that forms part of a consumable comprising aerosol generating material and is configured for use with a non-flammable aerosol supply device. Throughout this disclosure, the term consumable is sometimes referred to as an article of manufacture. This disclosure also relates to consumables or articles of manufacture including the component, and to systems including the device and the article of manufacture.

[0043] As used herein, the terms “upstream” and “downstream” are relative terms defined relative to the direction in which the mainstream aerosol is drawn through the product during use. The term “distal” (D) refers to the upstream end of the device, while “proximal” (P) refers to the downstream end of the device.

[0044] In some embodiments, a non-flammable aerosol supply system, particularly its non-flammable aerosol supply device, may include a power source and a controller. The power source may be, for example, an electric power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon matrix, which may be supplied with energy to distribute the power in the form of heat to the aerosol generating material or to a heat transfer material in the vicinity of the exothermic power source.

[0045] In some implementations, the non-flammable aerosol supply device includes an area for receiving consumables, an aerosol generator, an aerosol generation zone, a housing, a nozzle, a filter, and / or an aerosol modifier.

[0046] In some implementations, consumables used with a non-flammable aerosol supply device may include aerosol generating material, aerosol generating material storage area, aerosol generating material delivery assembly, aerosol generator, aerosol generating area, housing, wrapper, filter, nozzle and / or aerosol modifier.

[0047] Consumables include the substance to be delivered. The substance to be delivered is an aerosol generating material. Depending on the circumstances, the material may contain one or more active ingredients, one or more flavorings, one or more aerosol forming agents, and / or one or more other functional materials.

[0048] In some embodiments, the substance to be delivered comprises an active substance. As used herein, an active substance can be a physiologically active material, which is a material intended to achieve or enhance a physiological response. Active substances can be, for example, selected from nutritional supplements, nootropics, and psychoactive substances. Active substances can be naturally occurring or synthetically obtained. Active substances can contain, for example, nicotine, caffeine, taurine, theophylline, vitamins such as B6 or B12 or C, melatonin, or components, derivatives, or combinations thereof. Active substances can contain one or more components, derivatives, or extracts of tobacco or another plant product. In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0049] As described herein, an active substance may comprise or be derived from one or more plant products or their components, derivatives, or extracts. As used herein, the term "plant product" includes any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise a synthetically obtained active compound naturally present in plant products. The material may be in the form of a liquid, gas, solid, powder, dust, pulverized particles, granules, pellets, fragments, strips, sheets, etc. Exemplary plant products include tobacco, eucalyptus, star anise, hemp seeds, cocoa, fennel, lemongrass, peppermint, spearmint, rooibos tea, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, teas such as green or black tea, thyme, cloves, cinnamon, coffee, anise, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, red chili pepper, rosemary, saffron, lavender, lemon peel, peppermint, juniper, elderflower, vanilla, holly, and beefsteak. Plant), curcumin, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, nutmeg, damien, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theophylline, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint can be selected from the following mint varieties: wild mint (Mentha Arventis), Mentha cv, Mentha niliaca, peppermint (Menthapiperita), lemon mint (Mentha piperita citrata cv), Mentha piperita cv, spearmint (Mentha spicata crispa), Mentha cardifolia, European mint (Memtha longifolia), pineapple mint (Menthasuaveolens variegata), lip mint (Mentha pulegium), Mentha spicatac.v., and apple mint (Mentha suaveolens).

[0050] In some embodiments, the active substance comprises or is derived from one or more plant products or their components, derivatives or extracts, and said plant product is tobacco.

[0051] In some embodiments, the active substance comprises or is derived from one or more plant products or their components, derivatives or extracts, and said plant products are selected from eucalyptus, star anise, cocoa and hemp seeds.

[0052] In some embodiments, the active substance comprises or is derived from one or more plant products or their components, derivatives or extracts, and said plant products are selected from rooibos tea and fennel.

[0053] In some implementations, the substance to be delivered contains a flavoring agent.

[0054] As used herein, the terms “flavor” and “flavorant” refer to materials that, where permitted by local regulations, may be used in products intended for adult consumers to create a desired taste, aroma, or other sensory experience. These may include naturally occurring flavoring materials, botanical products, plant extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, liquorice, hydrangea, eugenol, Japanese white bark magnolia leaf). Leaf), chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, raspberries, cranberries, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot Geranium, Khat, Naswar, Areca, Shisha, Pine, Honey Essence, Rose Oil, Vanilla, Lemon Oil, Orange Oil, Orange Blossom, Cherry Blossom, Cinnamon, Caraway, Cognac, Jasmine, Ylang Ylang, Sage, Fennel, Wasabi, Piment, Ginger, Coriander, Coffee, Hemp Seeds, Peppermint Oil from Any Species of the Peppermint genus, Eucalyptus, Star Anise, Cocoa, Lemongrass, Rooibos Tea, Flax, Ginkgo, Hazelnut, Hibiscus, Bay Leaf, Mate, Orange Peel, Rose, Tea such as Green or Black Tea, Thyme, Juniper, Elderflower, Basil, Bay Leaf, Cumin, Oregano, Red Pepper, Rosemary, Saffron, Lemon Peel, Peppermint, Beefsteak Plants, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, nutmeg, damien, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor blockers, sensory receptor activators or stimulants, sugars and / or artificial sweeteners (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamates, lactose, sucrose, glucose, fructose, sorbitol or mannitol), and other additives such as charcoal, chlorophyll, minerals, plant products, or breath fresheners.They can be imitations, synthetic or natural ingredients, or blends thereof. They can be in any suitable form, such as liquids like oils, solids like powders, or gases.

[0055] In some embodiments, the flavoring agent comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent comprises flavor components of cucumber, blueberry, citrus fruits, and / or cranberry. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises flavor components extracted from tobacco.

[0056] In some embodiments, the flavoring agent may contain sensory agents designed to achieve somatosensory sensations that are typically chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) (in addition to or in place of aromatonic or gustatory nerves), and these may include agents that provide warming, cooling, tingling, or numbing effects. Suitable thermal effectors may be, but are not limited to, vanillyl alcohol, and suitable cooling agents may be, but are not limited to, eucolyptol, WS-3.

[0057] Aerosol generating materials are materials that can generate aerosols, for example, when heated, irradiated, or otherwise powered. Aerosol generating materials can be in solid, liquid, or gel form, and may or may not contain active substances and / or fragrances. Aerosol generating materials are incorporated into articles used in aerosol generating systems.

[0058] As used herein, the term "tobacco material" means any material containing tobacco or its derivatives or substitutes. Tobacco material can be in any suitable form. The term "tobacco material" can include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material can include one or more of ground tobacco, tobacco fiber, cut tobacco, compressed tobacco, tobacco stems, tobacco leaves, reconstituted tobacco, and / or tobacco extracts.

[0059] Consumables are articles containing or composed of aerosol generating materials, which are intended, in whole or in part, to be consumed during user use. Consumables may include one or more other components, such as an aerosol generating material storage area, an aerosol generating material delivery assembly, an aerosol generating area, a housing, packaging paper, a nozzle, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, particularly a heating element, which dissipates heat to cause the aerosol generating material to generate an aerosol during use. The heater may include a material or sensor that is heatable by electrical conduction.

[0060] Aerosol modifiers are substances typically located downstream of the aerosol generation zone, configured to modify the generated aerosols, for example, by altering their taste, flavor, acidity, or other properties. Aerosol modifiers can be incorporated into aerosol modifier release components, operable to selectively release the aerosol modifier.

[0061] Aerosol modifiers can be, for example, additives or adsorbents. Aerosol modifiers can include, for example, one or more of fragrances, colorants, water, and carbon adsorbents. Aerosol modifiers can be, for example, solids, liquids, or gels. Aerosol modifiers can be in powder, filament, or granular form. Aerosol modifiers may not contain filter materials.

[0062] An aerosol generating apparatus is an device (apparatus) configured to generate aerosols from aerosol generating materials. The aerosol generating apparatus includes a heater configured to subject the aerosol generating materials to heat energy to release one or more volatiles from the aerosol generating materials to form an aerosol.

[0063] The filament tow materials described herein may include cellulose acetate fiber bundles. Filament tows may also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4-butylene glycol succinate) (PBS), poly(butylene glycol adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers or combinations thereof. The filament tow may be plasticized with a suitable tow plasticizer, such as triacetin in the case of cellulose acetate bundles, or the tow may be unplasticized. The tow may have any suitable specifications, such as fibers with a “Y” shape or other cross-sections such as an “X” shape, a filament denier value between 2.5 and 15 deniers / filament, for example between 8.0 and 11.0 deniers / filament, and a total denier value between 5,000 and 50,000, for example between 10,000 and 40,000.

[0064] In the accompanying drawings described herein, the same reference numerals are used to indicate equivalent features, articles, or components.

[0065] Figure 1 This is a longitudinal cross-sectional view of aerosol generating article 1, which constitutes part of an aerosol delivery system including an aerosol delivery device 100 (see [link]). Figure 5 and 6 ).

[0066] Article 1 has an upstream or distal end “D” and a downstream or proximal end “P”, as well as a longitudinal axis XX. The proximal end P includes a nozzle 2, which may contain cellulose acetate filter material and may contain a capsule 3 containing an aerosol modifier or liquid fragrance. In alternative embodiments, the nozzle 2 may be a hollow tubular element and / or the capsule 3 may be omitted. An aerosol generating section 4 is connected to the nozzle 2. In this example, the aerosol generating section 4 includes a rod of aerosol generating material 5. The aerosol generating material 5 may comprise multiple strands or strips of aerosol generating material 5 and is circumscribed by a circumscribed paper 6, which may include one or more layers. The circumscribed paper 6, or one of its layers, may be aluminum foil. In other embodiments, the circumscribed paper 6 may be made of one or more paper layers, optionally containing a barrier coating to make the material of the circumscribed paper 6 substantially moisture-proof.

[0067] The aerosol generating section 4 includes a cooling element 7 positioned downstream of the aerosol generating material 5 and adjacent to the nozzle 2. The cooling element 7 includes a hollow channel 8 with an inner diameter between about 1 mm and about 4 mm, for example, between about 2 mm and about 4 mm. In this example, the hollow channel 8 has an inner diameter of about 3 mm. The hollow channel 8 extends along the entire length of the cooling element 7. The hollow channel 8 provides a space in which aerosols drawn from the rod of the aerosol generating material 5 into the cooling element 7 expand and cool. The cooling element 7 can be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first upstream end (D) of the cooling element 7 and the heated volatile component exiting the second downstream end (P) of the cooling element 7. Ventilation is provided directly in the cooling element 7 via at least one row of perforations 9 extending through the outer wall.

[0068] The cooling element 7 has a wall thickness in the radial direction. For a given outer diameter, the wall thickness of the cooling element 7 defines the inner diameter of the channel 8 surrounded by the wall of the cooling element 7. The cooling element 7 has a wall thickness of at least about 1.5 mm and at most about 2 mm. In this example, the cooling element 7 has a wall thickness of about 2 mm.

[0069] The cooling element 7 can be formed from a bundle of filaments. The wall material of the cooling element 7 can be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol generating material 5 passes longitudinally through the channel 8 of the cooling element 7, rather than through the wall material of the cooling element 7. For example, at least 92% or at least 95% of the aerosol generated by the aerosol generating material 3 passes longitudinally through the hollow channel 8.

[0070] like Figure 1 As shown, article 1 may include a plug 10 at the distal end D. In this embodiment, a heating element is inserted into the aerosol generating material 5 via the plug 10. Figure 1In one implementation, the plug 10 is tubular, although it can also be a cylindrical solid element.

[0071] In an embodiment of the invention, a tubular assembly 11 is disposed between the aerosol generating material 5 and the cooling element 7. The tubular assembly 11 is hollow and comprises a material body 12 surrounded by an outer packaging material layer 13, which may be plug wrap or other packaging paper. The tubular assembly 11 has a radial wall thickness greater than that of the cooling element 7. For example, the wall thickness of the tubular assembly 11 may be approximately 3.5 to 4 mm. The tubular assembly 11 is also shorter than the cooling element 7 and may have a typical length of approximately 7 mm.

[0072] Due to its increased wall thickness relative to the cooling element 7, the tubular assembly 11 is a structural element of the aerosol generating article 1 and provides improved rigidity to the aerosol generating article 1, making it more capable of withstanding axial compressive forces and bending moments that occur during manufacturing and in use. Furthermore, because the tubular assembly 11 is hollow, it does not impede the flow of aerosols compared to a solid cylindrical filter element. The increased wall thickness also makes the tubular assembly 11 more flexible and able to withstand moisture intrusion for a longer period without collapsing or buckling.

[0073] Through the tubular assembly 11 according to one embodiment of the invention and along Figure 1 A cross-sectional view taken from line AA is shown in Figure 2a. In this embodiment, the material body 12 comprises a plurality of identical, circumferentially spaced elongated strips or lines 12a that extend parallel to the longitudinal axis XX along the length of the hollow tubular assembly 11 (see Figure 2a). Figure 1Each strip is equally spaced in the circumferential direction around axis XX and extends radially inward from the inner surface of the outer sheet toward the longitudinal axis XX of the assembly. One or more of the strips 12a may have different cross-sectional shapes, but as shown in FIG. 2a, each strip 12a is identical and narrows or tapers in the radially inward direction toward the longitudinal axis XX. Each strip terminates at a tip 14 spaced apart from the longitudinal axis XX, which may be closer to the longitudinal axis XX than to the sheet 13. The tip 14 of each strip 12a may be shaped such that the edge 15 of each strip 12a extending between the inner surface of the sheet 13 and the tip 14 is spaced apart from but parallel to the opposite edge of the adjacent strip 12a. In another embodiment, the edges 15 of adjacent strips 12a or at least a portion of the edges of adjacent strips 12a may contact each other. The tip 14 of each strip 12a may include a surface extending circumferentially around the longitudinal axis XX. This surface may be arcuate and have a radius of curvature coaxially centered with the longitudinal axis XX.

[0074] Each strip 12a may be formed from multiple layers of paper or paper-laminated material, from foam material, from one or more nonwoven cellulose layers, or from a combination of these or different layers of nonwoven sheet material. The method of manufacturing the tubular element 11 using these or other materials is described in more detail below. The use of paper-based and / or cellulose materials in the construction of the tubular assembly avoids the use of plastic materials, and particularly single-use plastic materials. This has the advantage of making the tubular element recyclable or compostable. It also reduces the weight of the tubular assembly and the aerosol-generating articles in which the tubular assembly forms part.

[0075] along Figure 1 A cross-sectional view taken by line AA through the tubular assembly 11 according to another embodiment of the invention is shown in FIG. 3a. In this embodiment, the material body 12 has an annular cross-section and is tubular in shape. The material body 12 extends along the length of the tubular assembly 11.

[0076] As described above with reference to FIG. 2a, the material body 12 can be formed of multiple material layers. These multiple layers can be sequentially applied to the packaging material layer 13. In any embodiment of the invention, the material body can be formed of regenerated cellulose.

[0077] along Figure 1A cross-sectional view taken by line AA through the tubular assembly 11 according to another embodiment of the invention is shown in FIG. 4a. In this embodiment, the material body 12 has a tubular cross-section and extends along the length of the tubular assembly 11, but its inner surface facing the longitudinal axis XX is irregular in shape. The material body 12 may be formed of paper or paper layers. At least some of the paper or paper layers may be wrinkled or corrugated. The inner surface 12b of the material body 12 may have a regular or irregular pattern extending circumferentially around the longitudinal axis XX.

[0078] In any tubular assembly 11 according to an embodiment of the invention, an inner layer or inner sheet (not shown) may be present as a liner for the material body 12. The inner layer or inner sheet may be tubular. Both the inner and outer sheets may be coaxial with the longitudinal axis of the aerosol generating article.

[0079] A tipping paper (not shown) can be wrapped around the entire length of the nozzle 2 and the aerosol generating section on the packaging paper 4 to connect the nozzle 2 to the aerosol generating section.

[0080] A non-flammable aerosol supply system 15, including device 16 and aerosol generating article 1 housed in device 16, is shown in a simplified manner. Figure 5 As shown, the non-flammable aerosol supply device 16 has a housing 17, which includes a recess 18 for accommodating the aerosol generating article 1 therein, and in which a heater 19 is inserted into the aerosol generating material of the article 1.

[0081] like Figure 6 As shown, a power supply 20, such as a rechargeable lithium-ion battery pack, is housed within the housing 17. A controller 21 is connected to the heater, the power supply 20, and a user interface 22, such as a button or display. The controller 21 controls the power supplied to the heater 19 to regulate its temperature. Typically, the aerosol forming matrix 5 is heated to a temperature between 250 and 450 degrees Celsius.

[0082] A method for manufacturing a tubular assembly 11 according to an embodiment of the invention will now be described. Figure 2b shows a sheet of material 13 on which a material body 12 has been applied in the form of spaced parallel elongated strips or lines before being shaped into the tubular assembly 11 shown in Figure 2a, and this is achieved by winding it around the longitudinal axis XX. It will be understood that only a short length of the packaging material layer 13 is shown in Figure 2b, and the layer 13 can extend continuously in the longitudinal direction, i.e., it can be fed from a reel or bobbin (not shown), which is used to form an elongated tubular rod, which is then cut into individual tubular assemblies 11 by cutting the rod at repeated intervals perpendicular to the longitudinal axis XX.

[0083] The method according to an embodiment of the invention includes applying the material body 12 to a portion or the entire surface of the packaging material layer 13 before molding the layer 13 together with the material body 12 applied thereto into a tubular assembly 11. The material 12 can be sprayed, laid, or otherwise applied to the layer 13 while the layer 13 remains in a planar or flat configuration, or it can be applied while the layer 13 is being manipulated into a tubular form, i.e., it can be applied when the layer 13 has already taken on a curved cross-sectional profile but before the tubular shape is fully formed. If the material body 12 is sprayed or applied to the surface of the layer 13, the material body 12 can be allowed to cure before the layer 13 together with the material body 12 applied thereto into a tubular assembly 11.

[0084] In some cases, adhesives can be used to bond the material body 12 to the layer 13. The adhesive can be applied to the layer 13 before the material body 12 is applied. The material body 12 can be applied to the surface of the layer 13 to the desired thickness in one or more applications. For example, the material body 12 can consist of layers, each applied sequentially to the packaging material layer 13. Adhesives can be used to adhere each layer to the previously applied layer.

[0085] The layers or each layer forming the material body can be formed from a nonwoven sheet material (such as paper) or in the form of fiber bundles (such as cellulose). In some applications, it may be suitable to use layers formed from different materials. For example, one layer may be formed from nonwoven cellulose, while another layer may be formed from paper. Regardless of whether the paper is used in combination with any other material or layer, the paper may be wrinkled and / or formed from strips, or the paper may have a corrugated or other irregularly shaped profile. If the material body is applied in the form of strips, as described with reference to FIG. 2a, adjacent strips 12a may be formed from different materials.

[0086] Nonwoven sheet materials or fiber bundles typically contain multiple fibers. In some embodiments, the filter material according to this disclosure (in the form of a nonwoven sheet or fiber bundle) may be formed from alternative or recycled fiber materials. Such alternative fiber materials may advantageously provide improved biodegradability and / or reduced plasticity compared to the types of fiber inputs used in conventional cigarette filters (e.g., cellulose acetate). In some embodiments, the material body prepared according to this disclosure may contain multiple fibers selected from regenerated cellulose, hemp seeds, sisal, kenaf, esparto, jute, flax, wood, reconstituted tobacco, and combinations thereof. As used herein, the term "fiber" is defined as a basic element of textiles. It should be noted that the material body of this disclosure may include any of the aforementioned fiber input materials, alone or in combination with one or more other fiber input materials. Fibers are typically in the form of rope-like or thread-like elements. As used herein, the term "fiber" is intended to include fibers, filaments, continuous filaments, staple fibers, etc.

[0087] In some embodiments, the material body as described herein may specifically comprise regenerated cellulose fibers. It should be noted that the material body may comprise only regenerated cellulose fibers, or the regenerated cellulose fibers may be combined with one or more other fiber input materials as described herein. Regenerated cellulose fibers are typically prepared by extracting a non-cellulose compound from wood, contacting the extracted wood with caustic soda, subsequently with carbon disulfide, and then with sodium hydroxide to obtain a viscous solution. This solution is then forced through a spinneret to form viscous threads of regenerated fibers. Exemplary methods for preparing regenerated cellulose are provided in U.S. Patent No. 4,237,274 to Leoni et al.; U.S. Patent No. 4,268,666 to Baldini et al.; U.S. Patent No. 4,252,766 to Baldini et al.; U.S. Patent No. 4,388,256 to Ishida et al.; U.S. Patent No. 4,535,028 to Yokogi et al.; U.S. Patent No. 5,441,689 to Laity; U.S. Patent No. 5,997,790 to Vos et al.; and U.S. Patent No. 8,177,938 to Sumnicht, which are incorporated herein by reference. The methods of manufacturing regenerated cellulose are not limiting and may include, for example, rayon processes and TENCEL processes. Various suppliers of regenerated cellulose are known, including Lenzing (Austria), Cordenka (Germany), Aditya Birla (India), and Daicel (Japan). Examples of regenerated cellulose fibers include, but are not limited to, rayon, viscose, viscose rayon, lyocell fibers, etc.

[0088] To form the packaging material layer 13 and the material body 12 applied thereto into a tubular assembly 11, it can be drawn onto and wound around a cylindrical mandrel (not shown). In some embodiments, the layer 13 and the material body 12 applied thereto can be wound around the mandrel in a helical manner. The layer 13 may have an edge 13a on which no material body 12 is applied, and which overlaps with another edge of the layer 13 when the layer 13 and the material body 12 applied thereto have been formed into the tubular assembly 11. An adhesive can be applied to the edge 13a so that it adheres to the layer in the overlapping area, thereby maintaining the tubular form of the assembly 11 after it has been wound around the mandrel and removed from the end of the mandrel.

[0089] The method for forming the hollow tubular assembly 11 of FIG. 3a is similar to the method described above with reference to FIG. 2b, except that a single wide material strip 12 is applied to the packaging material layer 13 in one or more layers. As in the embodiment of FIG. 2b, the hollow tubular assembly 11 is formed as follows: the layer 13 to which the material body 12 has been applied is wound around a cylindrical mandrel to form a hollow elongated rod, and then cut at spaced intervals to form a plurality of hollow tubular assemblies 11.

[0090] The method for forming the hollow tubular component 11 of FIG. 4a is similar to the method described above with reference to FIG. 2b, except that the material body 12 applied to layer 13 is corrugated, wrinkled, or otherwise has an irregular shape. Material 12 can be applied in layers. The first layer in contact with the sheet can be bonded thereto with adhesive. Subsequent layers can then also be bonded to the previously applied layers using adhesive.

[0091] Once sufficient layers have been applied to provide the required thickness to the material body 12, the packaging material layer 13, together with the material 12 applied thereto, can be formed into a hollow tubular rod by winding it around a mandrel, as described above. The rod is then cut at spaced intervals into multiple individual hollow tubular assemblies 11 so that the individual tubular assemblies can be inserted into the aerosol generating article 1.

[0092] The various embodiments described herein are presented only to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or on the equivalents of the claims, and other embodiments can be utilized and modifications can be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, constitute, or substantially constitute suitable combinations of, the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, this disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. A method of manufacturing a tubular assembly of an aerosol generating article for use in a non-flammable aerosol delivery system, comprising applying a flexible material body to a packaging material layer, and subsequently forming the layer together with the material body applied thereon into a tubular assembly, wherein the material body is surrounded by the packaging material layer.

2. The method of claim 1, further comprising applying the material body to the layer while the layer is substantially planar.

3. The method according to claim 1 or 2, further comprising applying the material body onto the layer to a thickness greater than the thickness of the layer.

4. The method according to any one of the preceding claims, comprising forming the layer and the material body applied thereto together into a tubular assembly by winding the layer together with the material body applied thereto around a cylindrical mandrel.

5. The method of claim 4, wherein the method of forming the layer together with the material body applied thereto into a tubular assembly comprises applying an adhesive to the layer such that the edges of the layers that are in contact with each other when the layers are wound around a cylindrical mandrel are bonded together.

6. The method according to any one of the preceding claims, comprising adhering the material body to the layer with an adhesive.

7. The method according to any one of the preceding claims, wherein the material body is a nonwoven sheet material or fiber bundle, such as cellulose, and the method comprises applying the nonwoven sheet material or fiber bundle to the layer.

8. The method of claim 7, wherein the material body is paper, and the method includes applying the paper to the layer.

9. The method of claim 8, further comprising wrinkling or corrugating the paper before applying it to the layer.

10. The method according to any one of the preceding claims, comprising applying the material body in layers to the packaging material layer.

11. The method of claim 10, further comprising applying the packaging material layer sequentially to the layer.

12. The method of claim 11, further comprising adhering the layers to each other with an adhesive.

13. The method according to any one of claims 1 to 5, comprising applying the material body in a liquid or other non-solid form to the packaging material layer, allowing it to cure first, and then shaping the packaging material layer and the material body applied thereon into a tubular assembly.

14. The method of claim 13, further comprising applying the material body to the packaging material layer by spraying, coating or printing.

15. The method according to any one of the preceding claims, comprising applying the material body to the packaging material layer in spaced elongated strips or lines such that, when the layer and the material body applied thereto are formed into a tubular assembly, the elongated strips or lines extend in a longitudinal direction parallel to the longitudinal axis of the tubular assembly.

16. The method of claim 15, further comprising applying the material body in spaced elongated strips or lines such that when the layer and the material body applied thereto are molded together into a tubular assembly, there are gaps between each strip.

17. The method according to any one of claims 1 to 15, comprising applying the material body to the layer such that it extends continuously across the layer.

18. The method of claim 17, further comprising applying the material body such that its thickness varies in a direction extending across the layer.

19. The method of claim 18, further comprising applying the material body such that its thickness varies in an irregular manner.

20. The method according to any one of the preceding claims, comprising the following steps: An elongated rod is formed by winding the layer together with the material body applied thereto around a mandrel, and then cutting the rod to form multiple individual tubular assemblies.

21. The method according to any one of the preceding claims, wherein applying the flexible body comprises applying a regenerated cellulose material to the packaging material layer.

22. A tubular assembly of an aerosol generating article for use in a non-flammable aerosol supply system, the tubular assembly having a longitudinal axis and comprising a material body surrounded by an outer packaging material layer, wherein the material body comprises a plurality of layers.

23. The tubular assembly of claim 22, wherein at least one of the plurality of layers is formed of a nonwoven sheet material or a bundle of fibers.

24. The tubular assembly of claim 22, wherein at least one of the plurality of layers is formed of cellulose.

25. The tubular assembly of claim 22, wherein at least one of the plurality of layers is formed of paper.

26. The tubular assembly of claim 23, wherein the paper is wrinkled and formed from strips.

27. The tubular assembly of claim 23, wherein the layer or each of the plurality of layers is formed of corrugated paper.

28. The tubular assembly according to any one of claims 21 to 25, wherein at least two of the plurality of layers are adhered to each other with an adhesive.

29. The tubular assembly according to any one of claims 21 to 26, wherein at least two of the plurality of layers are formed of the same or different materials.

30. The tubular assembly according to any one of claims 21 to 27, wherein the outer packaging material layer comprises paper.

31. The tubular assembly according to any one of claims 21 to 29, comprising an inner layer serving as a liner for the material body.

32. The tubular assembly of claim 30, wherein the inner layer comprises paper.

33. A tubular assembly of an aerosol generating article for use in a non-flammable aerosol supply system, the tubular assembly having a longitudinal axis and comprising a material body surrounded by an outer packaging material layer, wherein the material body comprises a plurality of longitudinally extending circumferentially spaced strips, each of which extends radially inward toward the longitudinal axis.

34. The tubular assembly of claim 28, wherein each strip extends parallel to the longitudinal axis.

35. The tubular assembly of claim 28 or 29, wherein each strip narrows in a radially inward direction toward the longitudinal axis.

36. The tubular assembly of claim 30, wherein each strip has a tip spaced apart from the longitudinal axis.

37. The tubular assembly of claim 31, wherein each strip is shaped such that the strip edge extending between the outer packaging material layer and the tip is parallel to the opposite edge of the adjacent strip.

38. The tubular assembly of claim 31 or 32, wherein the tip of each strip is radially closer to the longitudinal axis than to the outer packaging material layer.

39. The tubular assembly according to any one of claims 31 to 33, wherein the tip of each strip includes a surface extending circumferentially around the longitudinal axis.

40. The tubular assembly of claim 34, wherein the surfaces are arcuate and the axis of each surface is coaxial with the longitudinal axis of the tubular assembly.

41. The tubular assembly according to any one of claims 22 to 40, wherein the material body comprises a regenerated cellulose material.

42. An article for use in a non-flammable aerosol supply system including an aerosol generating device, said article comprising a hollow tubular component made by the method according to any one of claims 1 to 20.

43. An article of manufacture for use in a non-flammable aerosol supply system comprising an aerosol generating device, said article comprising a tubular component according to any one of claims 21 to 35.

44. A system comprising a non-flammable aerosol generator, the aerosol generator including a heating element and an aerosol generating article according to claim 36 or 37.

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